Method for producing 2,3,5-trimethyl benzoquinone by oxidation of 2,3,6-trimethylphenol

ABSTRACT

The invention relates to a method for producing 2,3,5-trimethyl benzoquinone or a compound containing 2,3,5-trimethyl benzoquinone, the method comprising the following steps: Oxidation of 2,3,6-trimethylphenol with oxygen or an oxygen-containing gas in a two- or multi-phase reaction medium in the presence of a catalyst or catalyst system containing at least one copper (II)-halide to a mixture containing 2,3,5-trimethyl benzoquinone, characterized in that the reaction medium contains water and at least one secondary aliphatic acyclic alcohol having 6 or more, preferably 7 or more, carbon atoms.

This application is a Division of application Ser. No. 14/902,231 filedon Dec. 30, 2015. Application Ser. No. 14/902,231 claims the benefit ofU.S. Provisional Application 61/841,946 filed on Jul. 2, 2013.Application Ser. No. 14/902,231 claims priority for Application13174688.5 filed on Jul. 2, 2013 in European Patent Office. The entirecontents of these applications are incorporated herein by reference intheir entirety.

The present invention provides a process for preparing2,3,5-trimethylbenzoquinone or a mixture comprising2,3,5-trimethylbenzoquinone, comprising the following step: oxidizing2,3,6-trimethylphenol with oxygen or an oxygen-containing gas in atwo-phase or multiphase reaction medium in the presence of a catalyst orcatalyst system at least comprising a copper(II) halide to give amixture comprising 2,3,5-trimethylbenzoquinone, wherein the reactionmedium comprises water and at least one secondary aliphatic acyclicalcohol having 6 or more, preferably 7 or more, carbon atoms.

A further aspect of the present invention relates to a mixturecomprising 2,3,5-trimethylbenzoquinone, the mixture being preparable orprepared by the process of the invention.

The present invention additionally provides the use of a secondaryaliphatic acyclic alcohol having 6 or more, preferably 7 or more, carbonatoms as solvent in the oxidation of 2,3,6-trimethylphenol to2,3,5-trimethylbenzoquinone.

Furthermore, the present invention relates to the use of the2,3,5-trimethylbenzoquinone prepared by the process of the invention, orof a mixture comprising 2,3,5-trimethylbenzoquinone and prepared by theprocess of the invention, in the synthesis of vitamin E, moreparticularly for the preparation of 2,3,6-trimethylhydroquinone.

2,3,6-Trimethylbenzoquinone (1) is of great importance as a precursorfor the industrial synthesis of α-tocopherol, i.e., vitamin E (3). Forthis synthesis, (1) is first catalytically hydrogenated to2,3,6-trimethylhydroquinone (2), and then subjected to condensation withisophytol, using a Lewis acid as catalyst, to form (3) (scheme 1).

There are a series of industrially realized syntheses known for thesynthesis of (1). Almost all of the processes known from the prior artsynthesize (1) using the oxidation of 2,3,6-trimethylphenol (4), whichin turn can be obtained by a variety of routes. For the oxidation of (4)to (1), oxygen is used preferably, as an inexpensive oxidizing agent(scheme 2).

The most efficient processes for the oxidation of (4) to (1) usecopper(II) halides or copper(II)-halogen complexes as catalysts. Theseprocesses, however, are not without their attendant problems. Instancesinclude, for example, the costly and inconvenient recycling of thesolvent used and/or of the catalyst used, and, in particular, theformation of unwanted byproducts. Particularly noteworthy is theformation of halogenated, generally chlorinated, byproducts, which breakdown during workup, releasing HCl, and so lead to corrosion and tolosses of the product (1) of value.

DE 2 221 624 describes the oxidation of 2,3,6-trimethylphenol withoxygen in the presence of copper halides, primarily copper(II) chloridedihydrate, in polar solvents which are water-soluble or of unlimitedmiscibility with water—preferably dimethylformamide. A disadvantage ofthis process, however, is that it is difficult to isolate the productfrom the reaction mixture and to return the catalyst.

EP 127 888 describes the use of copper(II)-halide complexes having thegeneral formula M_(l)[Cu(II)_(m)X_(n)]_(p), such as Li[CuCl₃] orK₂[CuCl₄], for example, as catalysts for the oxidation of2,3,6-trimethylphenol with oxygen in a mixture of water and an aliphaticalcohol having 4 to 10 carbon atoms as solvent. Because the solventexhibits a miscibility gap with water, the reaction takes place in amixture composed of two liquid phases. As a result, high reaction ratesare achieved, and the catalyst is easy to return, as an aqueoussolution, by means of a phase separation. The aliphatic alcohols usedmay comprise 4 to 10 carbon atoms, preferably 5 to 10 carbon atoms.Preferred solvents stated are primary alcohols, examples beingn-butanol, n-amyl alcohol, isoamyl alcohol, n-hexanol, 2-ethylhexanol,n-heptanol, n-octanol, n-nonanol, and n-decanol.

EP 167 153 describes the use of the same catalyst as in EP 127 888 in amixture of water and aliphatic alcohols having 5 to 10 carbon atoms assolvents. Stated with preference are primary alcohols, as for examplen-amyl alcohol, isoamyl alcohol, n-hexanol, 2-ethylhexanol, n-heptanol,n-octanol, n-nonanol, and n-decanol. The reaction is carried out in“semibatch” mode, meaning that fewer byproducts are formed. Thereaction, furthermore, is easier to control, and less catalyst isrequired.

EP 294 584 describes the use of a mixture of copper(II) chloride andlithium chloride as catalyst, and, as solvent, an aqueous mixture of anaromatic hydrocarbon and an aliphatic alcohol having 1 to 4 carbonatoms. Stated by way of example are the primary alcohols methanol,ethanol, n-propanol, isopropanol, n-butanol, 2-butanol, andtert-butanol. A number of secondary and tertiary alcohols are in factstated, but only in combination with an aromatic hydrocarbon.Furthermore, these alcohols have a maximum of 4 carbon atoms. Thecomparison of examples 9 and 11 of EP 294 584, moreover, shows that theuse of isopropanol as secondary alcohol leads to lower yields than theuse of n-propanol (91.6 against 94.1%, under otherwise identicalconditions). Furthermore, the use of a solvent mixture results in asignificantly complicated solvent recycling procedure.

EP 369 823 describes the use of copper(II) chloride in combination withcertain nitrogen compounds (hydroxylammonium salts, oximes, or ammoniumsalts) as catalyst. Solvents used are preferably aliphatic alcoholshaving 3 to 10 carbon atoms, those used with particular preference beingbranched alcohols having 3 to 6 carbon atoms and, with very particularpreference, tertiary alcohols, such as tert-butanol or tert-amylalcohol. However, the best yields of (1) that are achieved here (example55: 94.5% with tert-amyl alcohol and 95% with tert-butanol) are situatedat best at the same level as described in earlier specifications in theprior art that do not require the addition of nitrogen compounds.

M. Shimizu et al. (Bull. Chem. Soc. Jpn. 65 (1992) 1522) disclose aprocess for oxidizing (4) using mixtures of Cu(II) chloride andhydrochlorides of various amines, hydroxylamine, or oximes as catalystsystem. Here again, solvents used include not only primary alcohols butalso secondary alcohols, such as isopropanol, sec-butanol, 2-pentanoland 3-pentanol, tert-butanol, and tert-amyl alcohol, without anyparticular advantage becoming evident for the use of secondary alcohols.The preferential use of hydroxylamine as an adjuvant, which is consumedin the oxidation, makes this process unattractive.

EP 475 272 describes the use of mixtures of copper(II) chloride andalkaline earth metal chlorides, especially MgCl₂, as catalyst. Solventslisted are saturated aliphatic alcohols having 5 to 10 carbon atoms.Stated as particularly preferred are 1-pentanol, 1-hexanol, 1-heptanol,1-octanol, 1-nonanol, 1-decanol, 2-ethyl-1-hexanol, and cyclohexanol—inother words, apart from cyclohexanol, primary alcohols.

EP 1 092 701 describes the use of mixtures of copper(II) chloride andother metal chlorides from the group of Fe, Cr, Mn, Co, Ni, Zn, or rareearths as catalysts. Solvents listed are branched and unbranchedaliphatic alcohols having 5 to 10 carbon atoms. Stated as particularlypreferred are 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, 1-nonanol,1-decanol, 2-ethyl-1-hexanol, and cyclohexanol—in other words, apartfrom cyclohexanol, primary alcohols.

JP 55 072 136 describes the use of copper(II) chloride dihydrate as acatalyst in polyethylene glycols, such as CH₃O(CH₂CH₂O)₉CH₃, forexample, as solvent. The reaction mixture can be worked up aqueously inorder to return the catalyst. The desired product is removed bydistillation as a low boiler. A disadvantage of this process, however,is that high-boiling byproducts become concentrated in the solvent andare difficult to remove.

Like all processes based on Cu halide catalysts, then, the processesdescribed above also have fundamental disadvantages originating from theformation of organochlorine byproducts. These byproducts come aboutduring the implementation of the oxidation reaction, and result from thechlorination of the reactant (4), of the product (1), and optionally ofthe 1-hexanol solvent. Below shows a number of typical byproducts, butwithout giving a complete listing.

Above shows typical byproducts in the oxidation of 2,3,6-trimethylphenol(4) to 2,3,6-trimethylbenzoquinone (1).

The chlorination reactions which occur have the effect of a direct lossof selectivity in the desired oxidation reaction, and also, possibly, aloss of solvent, which must be compensated by addition of fresh solvent.At the same time, the catalyst phase is depleted of chloride, and forthis reason the catalyst phase has to be treated with hydrochloric acidat regular intervals for the purpose of regeneration.

Furthermore, particularly under thermal load, the organochlorinebyproducts give off to hydrogen chloride, leading to significantcorrosion problems in the corresponding plant parts (e.g., indistillation columns in which the reaction mixture is heated), meaningthat expensive specialty steels have to be used for virtually all areasof the plant. Furthermore, hydrogen chloride induces decompositionreactions of the product (1) of value, leading to losses of yield,particularly in the liquid phase of the distillation column. Theorganochlorine byproducts (e.g., the compounds (7)-(11) shown in FIG. 1)generally having boiling points which are similar to that of the solventor to that of the product, thereby hindering the distillative separationof the reaction mixture and giving rise to both product Joss and solventloss in middle-boiler fractions. Chlorinated impurities also poison thehydrogenation catalyst in the subsequent reaction of the quinone (1) togive the hydroquinone (2).

In order to avoid these disadvantages, additional workup steps aregenerally carried out. EP 0 216 351 discloses a concept for the removalof organochlorine byproducts from crude discharges from the CuCl₂mediated oxidation of (4) to (1). Depletion of the byproducts isaccomplished here by base scrubbing. Base scrubbing, however, is notparticularly effective, and always implies a compromise betweenreduction in organochlorine compounds and losses of product. Overall,this measure does permit technical realization of the process accordingto scheme 3, but the additional process step represented by the basescrub results in higher capital costs and production costs, in losses ofyield, and therefore, all in all, only to an alleviation of the problemdescribed here.

A primary object of the present invention, accordingly, is to provide aprocess for preparing 2,3,5-trimethylbenzoquinone or a mixturecomprising 2,3,5-trimethylbenzoquinone by oxidation of2,3,6-trimethylphenol in the presence of a catalyst or catalyst systemat least comprising a copper(II) halide, said process having all of theadvantages of the processes known from the prior art, but minimizing theformation of the unwanted chlorinated byproducts.

A preferred object of the present invention is the provision of aprocess for preparing 2,3,5-trimethylbenzoquinone or a mixturecomprising 2,3,5-trimethylbenzoquinone by oxidation of2,3,6-trimethylphenol in the presence of a catalyst or catalyst systemat least comprising a copper(II) halide that very largely avoids theformation of chlorinated byproducts, in order thereby to improve theselectivity of the reaction, to minimize the solvent loss throughchlorination of the solvent, and optionally to avoid the need foradditional workup steps and for the use of specialty materials.

It has now surprisingly been found that through the use of a secondaryaliphatic acyclic alcohol having 6 or more, preferably 7 or more, carbonatoms as solvent in the oxidation of 2,3,6-trimethylphenol in thepresence of a catalyst or catalyst system at least comprising acopper(II) halide, it is possible greatly to suppress the formation ofchlorinated byproducts, while at the same time retaining all of theadvantages known from the prior art.

The present invention therefore provides a process for preparing2,3,5-trimethylbenzoquinone or a mixture comprising2,3,5-trimethylbenzoquinone, comprising the following step: oxidizing2,3,6-trimethylphenol with oxygen or an oxygen-containing gas in atwo-phase or multiphase reaction medium in the presence of a catalyst orcatalyst system at least comprising a copper(II) halide to give amixture comprising 2,3,5-trimethylbenzoquinone, wherein the reactionmedium comprises water and at least one secondary aliphatic acyclicalcohol having 6 or more, preferably 7 or more, carbon atoms.

With the process of the invention, there is no need to use specialtysteels or to have a base scrub. During the pure effective distillation,the crude product is much more stable under thermal load, therebyminimizing losses in yield and at the same time producing a purer andhence more high-value product.

Suitable in principle for the process of the invention are all aliphaticacyclic alcohols which comprise 6 or more, preferably 7 or more, carbonatoms. Particularly preferred is the use of 3-heptanol.

In one advantageous refinement of the process of the invention, theoxidation of 2,3,6-trimethylphenol (4) is carried out with anoxygen-containing nitrogen gas in a two-phase reaction medium in thepresence of substoichiometric amounts of a CuCl₂ catalyst andstoichiometric amounts of LiCl (scheme 3).

Of the process of the invention, the formation of organochlorinebyproducts in the oxidation reaction of 2,3,6-trimethylphenol (4) to2,3,5-trimethylbenzoquinone (1) is greatly reduced.

As well as the significant reduction in the organochlorine byproducts,effluence from the oxidation reaction carried out in secondary alcoholsare found to have greatly reduced amounts of metal ions and chlorideions, and much less water. This facilitates the extraction for therecovery of the catalyst in solution in the organic phase. Since thephase separation during aqueous workup is much quicker, the workupapproach becomes shorter and easier, considerably, by comparison withthe use of primary alcohols as solvents. Given the fact, moreover, thatthe water-solubility of secondary alcohols is lower than that of primaryalcohols having the same number of carbons, there is also a reduction inthe solvent loss during the extraction.

In the advantageous refinement, described above, of the process of theinvention, the reaction mixture consists of a lower, aqueous catalystphase and of an upper, organic phase which comprises solvent, substrate,and reaction products. An oxygen-nitrogen stream is fed into thistwo-phase mixture with stirring. The process preferably takes placebatchwise.

In one advantageous refinement of the process of the invention, themixture comprising 2,3,5-trimethylbenzoquinone is washed in a step (ii)with an aqueous alkaline solution.

It is preferred in accordance with the invention, furthermore, for theoxidation to be carried out at a temperature of between 50° C. and 65°C., preferably at a temperature of between 53 and 58° C.

It is further preferred in accordance with the invention for theoxidation to be carried out over a period of 4 to 8 hours, preferablyover a period of 5-7 hours.

In one advantageous refinement of the process of the invention, thereaction medium, after oxidation has taken place, is subjected in a step(iii) to a phase separation, and the organic phase is extracted forrecovery of the catalyst in solution in the organic phase.

The present invention also provides a mixture comprising2,3,5-trimethylbenzoquinone, the mixture being preparable or prepared bythe process of the invention.

Through the process of the invention it is possible to obtain a mixturecomprising 2,3,5-trimethylbenzoquinone that has a chlorine content ofless than 0.5 g/100 g and/or a lithium content of less than 0.3 g/100 gand/or a copper content of less than 240 mg/kg.

The present invention additionally provides the use of a secondaryaliphatic acyclic alcohol having 6 or more, preferably 7 or more, carbonatoms as solvent in the oxidation of 2,3,6-trimethylphenol to2,3,5-trimethylbenzoquinone.

Furthermore, the present invention relates to the use of the2,3,5-trimethylbenzoquinone prepared by the process of the invention, orof a mixture comprising 2,3,5-trimethylbenzoquinone and prepared by theprocess of the invention, in the synthesis of vitamin E, moreparticularly for the preparation of 2,3,6-trimethylhydroquinone.

The invention is elucidated in more detail by the examples which follow.

Analysis:

At the end of the exemplary experiments, the phases were separated andseparately weighed, and the organic phases were analyzed. Quantitativedetermination of the amount of (1) and (4) in the organic phases tookplace by gas chromatography. The total chlorine content was determinedby elemental analysis, and the amount of chloride ions was determined bypotentiometric titration with a silver nitrate solution. The differencebetween the two values gives the amount of organically bonded chlorine.The quantitative determination of copper and lithium took place by meansof atomic emission spectroscopy (ICP-OES).

EXAMPLES 1 TO 10

A 4 L steel reactor was charged with 657 g of an aqueous reaction mediumconsisting of 151 g of CuCl₂.2H₂O, 150 g of LiCl, and 365 g of water,and with 818 g of the alcohol serving as solvent. With stirring, thistwo-phase mixture was brought to the desired starting temperature T_(D),and an oxygen-containing gas mixture was passed through it underatmospheric pressure. When the temperature T_(D) has been reached, a 60wt % strength solution of 500 g of 2,3,5-trimethylphenol (4) in thealcohol serving as solvent is supplied at a constant rate over a periodt_(D). In order to complete the reaction, stirring is continued at thetemperature T_(R) for a time span t_(R).

After the end of reaction and after cooling to room temperature, thephases are separated and weighed individually, and the organic phase isanalyzed. The conversion of (4) is complete in all cases (>99.9%). Thereis little variation in the yield of quinone (1), which in all of theexperiments is in the 90-95% range. The results are set out in table 1.

As shown by a comparison of the inventive examples (I 2, 4, 6, 8, 10)with the associated comparative examples (C 1, 3, 5, 7, 9), the amountsof organically bonded chlorine when the reaction is carried out in asecondary alcohol for inventive use are lower on average by a factor of3.5 than when using a primary alcohol. The total chlorine content,copper content, and lithium content of the organic phase is likewisemuch lower (on average by a factor of 6 for total chlorine, by a factorof 4.5 for copper, and by a factor of 18 for lithium).

TABLE 1 Results of the oxidation experiments (I: inventive, C:comparative experiments). Cl_(tot), Cl⁻, Cl_(organic), Cu, Li, No.Solvent t_(D), h T_(D), ° C. t_(R), h T_(R), ° C. O₂, SL/h N₂, SL/hg/100 g g/100 g g/100 g g/100 g mg/kg C1 1-hexanol 3.25 58 2.75 58 90 602.3 2.2 0.1 1.2 2100 I2 3-heptanol 3.25 58 2.75 58 90 60 0.31 0.27 0.040.22 70 C3 1-hexanol 2.00 53 4.00 65 90 60 2.5 2.3 0.2 1.1 2100 I43-heptanol 2.00 53 4.00 65 90 60 0.31 0.26 0.05 0.21 65 C5 1-hexanol1.00 53 5.00 58 150 0 2.2 2.1 0.1 1.1 1800 I6 3-heptanol 1.00 53 5.00 58150 0 0.29 0.28 0.01 0.21 60 I7 3-heptanol 1.00 53 5.00 1 h, 53° C. 1500 0.34 0.27 0.07 0.21 70 4 h 58° C. I8 2-octanol 1.00 53 5.00 58 150 00.47 0.42 0.05 0.29 230 C9 1-heptanol 1.00 53 5.00 58 150 0 1.80 1.600.20 0.92 1500 C10 1-octanol 1.00 53 5.00 58 150 0 1.70 1.50 0.20 0.831300

EXAMPLE 11

A reaction effluent obtained from example 17 (reaction in 3-heptanol) isfirst washed with water. When phase separation has taken place theorganic phase is extracted by shaking with aqueous HCl (25 wt %) andthen washed with water again. Sodium hydroxide solution (2 wt %) isadded to bring the solution to a pH of 6, and the solvent is removedunder reduced pressure to an extent such as to give an approximately 75wt % strength solution of trimethylquinone (1).

In order to determine the thermal stability of this crude product, it isheated to 110° C. and the amount of (1) is determined at regularintervals by gas chromatography. After 125 hours, only 8% of the (1)originally present has undergone decomposition.

COMPARATIVE EXAMPLE 12

Example 11 was repeated with the effluent from example C1 (reaction in1-hexanol as solvent). On heating to 110° C., 44% of the quinone (1)originally present had undergone decomposition after 125 hours.

1-15. (canceled)
 16. A mixture comprising 2,3,5-trimethylbenzoquinonewhich has a copper content of less than 240 mg/kg.
 17. The mixture asclaimed in claim 16, wherein the mixture has a lithium content of lessthan 0.3 g/100 g.
 18. The mixture as claimed in claim 16, wherein themixture has a chlorine content of less than 0.5 g/100 g.
 19. The mixtureas claimed in claim 16, wherein the mixture has a copper content of lessthan 220 mg/kg.
 20. The mixture as claimed in claim 16, wherein themixture has a copper content from 210 to 220 mg/kg.
 21. The mixture asclaimed in claim 17, wherein the mixture has a copper content from 210to 220 mg/kg.
 22. The mixture as claimed in claim 16, wherein themixture has a chlorine content of less than 0.42 g/100 g.
 23. Themixture as claimed in claim 16, wherein the mixture has a chlorinecontent of from 0.26 g/100 g to 0.42 g/100 g.
 24. The mixture as claimedin claim 21, wherein the mixture has a chlorine content of from 0.26g/100 g to 0.42 g/100 g.
 25. A mixture comprising2,3,5-trimethylbenzoquinone, the mixture being prepare by a processcomprising 2,3,5trimethylbenzoquinone, comprising the following step:(i) oxidizing 2,3,6-trimethylphenol to 2,3,5-trimethylbenzoquinone withoxygen or an oxygen-containing gas in a two-phase or multiphase reactionmedium in the presence of a catalyst or catalyst system at leastcomprising a copper(II) halide, to give a mixture comprising2,3,5trimethylbenzoquinone, wherein the reaction medium comprises waterand at least one secondary aliphatic acyclic alcohol having 6 or morecarbon atoms.
 26. The mixture according to claim 25, wherein the mixturehas a chlorine content of less than 0.5 g/100 g.
 27. The mixtureaccording to claim 25, wherein the mixture has a lithium content of lessthan 0.3 g/100 g.
 28. The mixture according to claim 25, wherein themixture has a copper content of less than 240 mg/kg.
 29. The mixtureaccording to claim 26, wherein the mixture has a lithium content of lessthan 0.3 g/100 g.
 30. The mixture according to claim 29, wherein themixture has a copper content of less than 240 mg/kg.